Elevator for automated conveyor system

ABSTRACT

An elevator for specimen carriers includes an upper housing which is removably connected to an upstream end of an upper conveyor track and a lower housing which is removably connected to a downstream end of a lower conveyor track, the conveyor tracks being vertically spaced. Each conveyor track has a moving support surface which transports a specimen carrier downstream. The elevator includes a pair of opposingly disposed lift pins operably mounted along a chain housed within the elevator, the lift pins located to engage opposingly disposed wings on each specimen carrier, to lift the specimen carrier from the lower track to the upper track. The elevator housings are adjustably connected together, to permit adjustment of the overall height of the elevator for a variety of vertically spaced tracks.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation application of Ser. No. 08/418,942, filed Apr. 7,1995, which issued as U.S. Pat. No. 5,567,386.

TECHNICAL FIELD

The present invention relates generally to systems for the automation ofclinical laboratories and the like, and more particularly to an elevatorutilized with a conveyor track in an automated conveyor system fortransporting specimens throughout an automated laboratory.

BACKGROUND OF THE INVENTION

Clinical laboratory testing has changed and improved remarkably over thepast 70 years. Initially, tests or assays were performed manually, andgenerally utilized large quantities of serum, blood or othermaterials/body fluids. As mechanical technology developed in theindustrial work place, similar technology was introduced into theclinical laboratory. With the introduction of new technology,methodologies were also improved in an effort to improve the quality ofthe results produced by the individual instruments, and to minimize theamount of specimen required to perform a particular test.

More recently, instruments have been developed to increase theefficiency of testing procedures by reducing turnaround time anddecreasing the volumes necessary to perform various assays. Presentdirections in laboratory testing focus on cost containment proceduresand instrumentation. Laboratory automation is one area in which costcontainment procedures are currently being explored. Robotic engineeringhas evolved to such a degree that various types of robots have beenapplied in the clinical laboratory setting.

The main focus of prior art laboratory automation relies on theimplementation of conveyor systems to connect areas of a clinicallaboratory. Known conveyor systems in the laboratory setting utilizeseparate conveyor segments to move specimens from a processing stationto a specific laboratory work station. In order to obtain cost savings,the specimens were sorted manually, and grouped in a carrier rack to beconveyed to a specific location. In this way, a carrier would move agroup of 5-20 specimens from the processing location to the specificwork station for the performance of a single test on each of thespecimens within the carrier rack.

With the development of new and improved automatic conveyor systems forlaboratories and other environments, the inventors herein have found aneed for a customized conveyor track and support system for supportingthe conveyor track above the ground. Preferably, the track and supportsystem permits flexibility in the arrangement of tracks and "gates"accessing various work stations, as well as simple and economic moduleswhich are easily connected to customize the layout of the particularconveyor system.

In the prior art, conveyor track was conventional directly suspendedfrom a ceiling or a wall support. For this reason, each and everysection of conveyor track would necessarily be customized to fit aparticular location. In the event of a repair, or other mechanicalproblem, the entire conveyor track would need to be shut down and thepertinent section removed for repair or replacement. Because of thecustomized design of each automated conveyor system of the prior art,any replacement pieces would also necessarily be customized.

Prior art elevator systems typically utilized a vertically moveableplatform upon which a specimen carrier would rest during transport.However, it has been found that such prior art elevator systems arerelatively complex to employ in the automated laboratory conveyorsystems currently available, and typically do not provide for enclosedtransport to contain any spilled fluid during the movement of a specimenamong vertically displaced tracks.

Another problem with prior art elevator systems was in the time requiredto customize a particular elevator between two vertically displacedtracks. Most elevator systems required that the tracks be spaced apredetermined and uniform distance apart, in order to prevent customizedmanufacture of an elevator for a particular location. Unfortunately, onsite laboratory automation systems frequently require non-uniformmovement and locations. Thus, such unified vertical displacement wasrarely found in the typical laboratory setting.

A change in the type of elevator utilized in automated conveyor systemsalso requires the modification of the specimen carrier for use incombination with the elevator.

In the laboratory environment, it is common for the conveyor track totransport various fluid specimens among a plurality of work stations.One problem with prior art designs of conveyor track was in the factthat spillage of such fluid would contaminant the track and thesurrounding environment.

SUMMARY OF THE INVENTION

It is therefore a general object of the present invention to provide animproved elevator and specimen carrier for a modular conveyor track inan automated conveyor system.

Another object is to provide an elevator which includes features for theretention of fluid spillage, and to prevent the escape of fluid whichhas been spilled.

Yet another object of the present invention is to provide an elevatorwhich may be easily connected to a modular conveyor track in anautomated conveyor system.

A further object is to provide an elevator which is verticallyadjustable in length to extend between a variety of vertically displacedconveyor tracks.

Still another object is to provide an improved specimen carrier whichcooperates with an improved elevator to permit simple and efficientvertical transport of the specimen carrier from one conveyor track to asecond vertically displaced conveyor track.

These and other objects of the present invention will be apparent tothose skilled in the art.

The elevator for specimen carriers of the present invention includes anupper housing which is removably connected to an upstream end of anupper conveyor track and a lower housing which is removably connected toa downstream end of a lower conveyor track, the conveyor tracks beingvertically spaced. Each conveyor track has a moving support surfacewhich transports a specimen carrier downstream. This elevator includes apair of opposingly disposed lift pins operably mounted along a chainhoused within the elevator, the lift pins located to engage opposinglydisposed wings on each specimen carrier, to lift the specimen carrierfrom the lower track to the upper track. The elevator housings areadjustably connected together, to permit adjustment of the overallheight of the elevator for a variety of vertically spaced tracks.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the elevator of the present inventioninstalled between an upper and lower conveyor track;

FIG. 2 is an enhanced side elevational view of the elevator lowerhousing and lower track;

FIG. 3 is an enlarged perspective view of the lower housing of theelevator, with portions broken away for clarity;

FIG. 4 is a top elevational view of the elevator with the top plateremoved for clarity;

FIG. 5 is a front elevational view, with portions broken away;

FIG. 6 is a front elevational view, with the elevator in a retractedposition;

FIG. 7 is a front elevational view with the elevator in an extendedposition;

FIG. 8 is a perspective view of a specimen carrier used with theelevator;

FIG. 9 is a top elevational view of the specimen carrier;

FIG. 10 is a front elevational view of the specimen carrier; and

FIG. 11 is an end elevational view taken from the right side of FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, in which identical or corresponding partsare identified with the same reference numeral, and more particularly toFIG. 1, the elevator of the present invention is designated generally at10 and is shown connected between an upper conveyor track 12 and a lowerconveyor track 14, for the vertical transport of a specimen carrier 16therebetween.

Elevator 10 includes a lower generally L-shaped housing 18telescopically connected to an upper inverted L-shaped housing 20, withthe vertical back 18a of lower leg 18 inserted within the vertical back20a of upper housing 20. The horizontal leg 18b of lower housing 18 issecured to lower track 14, while the horizontal leg 20b of upper housing20 is secured to upper track 12.

Referring now to FIG. 2, conveyor track 14 is supported on a supportrail 22, which is connected to a plurality of hangers to supportconveyor track 14 above the ground. Support rail 22 has a generallyI-shaped cross-section with an upper horizontal plate 22a connected to alower horizontal plate 22b by a vertical web 22c. Upper plate 22aincludes a pair of upwardly projecting forward and rearward walls 22dand 22e, oriented parallel to web 22c. Upper plate walls 22d and 22eeach have an upper lip 22f and 22g, respectively, and inwardly towardsone another to form a pair of co-planar horizontal upper supportsurfaces.

Conveyor track 14 has a generally U-shaped cross-section with a forwardvertical leg 24 and a rearward vertical leg 26 connected by a generallyhorizontal base plate 28. A generally J-shaped fastener leg 30 dependsfrom the lower end of forward leg 24, below base plate 28. A rearwardJ-shaped fastener leg 32 depends from the lower end of rearward leg 26,below base plate 28, opposite to forward fastener leg 30. Base plate 28of lower track 14 is supported on the upper support surfaces of lips 22fand 22g of support rail 22, as shown in FIG. 2. Fastener legs 30 and 32receive the support rail upper walls 22d and 22e therebetween, such thattrack 14 engages support rail 22. Clips (not shown) interconnectfastener legs 30 and 32 with support rail 22 to securely fasten track 14to support rail 22.

An upper flange 34 projects forwardly and upwardly from a locationspaced below the upper end 24a of track forward leg 24. Upper flange 34thereby forms an upper support channel 36 between flange 34 and theforward face of forward leg 24. A lower flange 38 also projectsforwardly and upwardly from the forward face of forward leg 24, at aposition spaced below upper flange 36 and spaced above base plate 28.Lower flange 38 thereby forms a lower support channel 40 on the forwardsurface of forward leg 24 spaced below upper support channel 36.Rearward leg 26 is a mirror image of forward leg 24, and also includesan upper support channel 36' and lower support channel 40' thereon. Asshown in FIG. 2, upper and lower support channels 36, 36', 40 and 40'provide support for lower housing leg 18b, as described in more detailhereinbelow.

Referring now to FIG. 3, lower housing leg 18b includes a pair offorward and rearward opposing parallel plates 42 and 44 connected attheir upper ends by a top plate 46, to form a generally invertedU-shaped housing. A pair of hook members 48 are mounted on the inwardface of forward plate 42, each hook member 48 having an upper hook 48aand a lower hook 48b projecting inwardly and downwardly from an inwardface thereof, for engagement in the upper and lower support channels 36and 40 of conveyor track 14. A second pair of hook members 48' aremounted on the inward face of rearward plate 44, disposed oppositely ofhook members 48, with upper and lower hooks 48'a and 48'b engaged inupper and lower channels 36' and 40', as shown in FIG. 2. Set screws 50,threaded through apertures in forward and rearward plates 42 and 44engage the sides of track 14 to secure lower housing 18 in position.

Referring once again to FIG. 1, lower track 14 and support rail 22extend through lower housing 18, to project from the opposite endthereof. An end cap 52 is provided for the end of the projectingconveyor track 14 and support rail 22, and serves to retain any fluidsspilled within the conveyor track 14 from escaping from the track.

A removable cover 54 is provided for conveyor track 14, and has agenerally inverted U-shape and is preferably formed of a resilientmaterial such as plastic. Cover 54 snaps over the upwardly projectinglegs 24a and 26a of conveyor track 14 to form an enclosed housingthrough which specimen carriers 16 are transported.

Referring once again to FIG. 3, a pair of opposing co-planar end walls56 are mounted between lower housing forward and rearward plates 42 and44, with each end wall having an inwardly directed edge with a profilematching the profile of track 14 and the cover 54 (also shown in FIG.1). Thus, specimen carrier 16 remains enclosed as it is transportedalong conveyor track 14 into lower housing 18 of elevator 10.

As shown in FIGS. 3 and 4, the vertical back 18a of lower housing 18 isformed from a length of conveyor track 14' attached to a length ofsupport rail 22'. Top plate 46 of lower housing leg 18b has an apertureformed therein following the profile of track 14' and support rail 22',such that back 18a is fastened within housing 18b with screws 58, withtrack 14' projecting upwardly therefrom. A stop plate 58 is fastened tothe lower end of track 14' and depends therefrom to stop movement of aspecimen carrier 16 along lower track 14 in a position to permitengagement of lift pins 60 projecting from a pair of continuous loopchains 62, with projecting wings 64 on the specimen carrier 16, asdescribed in more detail hereinbelow.

Referring once again to FIG. 1, upper housing 20 includes a generallyL-shaped forward plate 66, a matching rearward plate 68 and a top plate70 connecting the upper ends of the forward and rearward plates 66 and68. As shown in FIGS. 4 and 5, a pair of hook members 72 are affixed tothe inward face of forward plate 66 so as to engage the upper and lowerchannels 36' and 40' of track 14', with a pair of set screws 74 engagingthe forward leg 24' to secure upper housing 20 in the desired positionalong track 14'. A pair of opposing hook members 76 and set screws 78are mounted through rearward plate 68 in a similar fashion toselectively engage the rearward leg 26' of track 14'. FIGS. 6 and 7 showthe overall height of elevator 10 adjusted between a shorter height andlonger height, to meet the particular requirements of the verticalspacing of a pair of vertically spaced conveyor tracks. By loosening andtightening set screws 74, upper housing 20 may be selectively secured atthe desired location along lower housing back 18a.

Referring to FIG. 5, it can be seen that upper housing 20 includes ahorizontally oriented support plate 80 affixed between the forward andrearward plates 68, on the bottom of the projecting leg 20b of housing20. Support plate 80 rests on the support rail 22" of upper conveyortrack 12. As shown in FIG. 5, support rail 22" projects beyond the endof upper conveyor track 12 specifically to accept support of upperhousing 20 of elevator 10. A stop plate 82 projects vertically betweenforward and rearward plates 66 and 68 of upper housing 20 and isoriented to contact the end of upper conveyor track 12, when properlypositioned within upper housing 20 of elevator 10.

As shown in FIG. 4 and 5, upper housing 20 is secured to upper conveyortrack 12 by set screws 84 extending through forward and rearward plates66 and 68 and biasing against the opposing sides of track 12.

The endless loop chains 62 are engaged around a plurality of pairs ofsprockets in order to raise or lower a specimen carrier 16 between upperand lower conveyor tracks 12 and 14. Since each sprocket shown in FIG. 5has an opposing coaxial sprocket associated therewith, only one set ofsprockets will be described in detail herein. A pair of lower sprockets86a and 86b are rotatably mounted within lower housing leg 18b andpreferably horizontally spaced apart from one another. Chain 62 includesa first horizontal leg extending beneath lower sprocket 86a and thencearound lower sprocket 86b and a second leg 62b extending verticallyupwardly from lower sprocket 86b to the first of a pair of uppersprockets 88a and 88b. Sprockets 88a and 88b are rotatably mounted andhorizontally spaced apart in the leg 20b of upper housing 20, with athird leg 62c of chain 62 extending from sprocket 88a to sprocket 88b. Apair of intermediate sprockets 90a and 90b are vertically spaced apartfrom one another and located below upper sprockets 88a and 88b and aremounted in upper housing 20. A third intermediate sprocket 90c isrotatably mounted on an upright 92 which projects upwardly from theupper end of lower housing back 18a. A fourth leg 62d of chain 62extends from upper socket 88b, and around the upper sprocket 90a ofintermediate sprockets 90a and b. A fifth leg 62e of chain 62 extendsvertically downwardly from sprocket 90a to sprocket 90b, thence upwardlyto form sixth leg 62f, and around third intermediate sprocket 90c. Theseventh leg 62g of chain 62 extends vertically from third intermediatesprocket 90c downwardly to the first lower sprocket 86a, to complete theloop.

Referring now to FIGS. 6 and 7, it can be seen that the adjustment ofvertical height of elevator 10 is accomplished by the use ofintermediate sprockets 90a, 90b and 90c. By locating third intermediatesprocket 90c vertically between sprockets 90a and 90b, with thirdsprocket 90c connected to the lower housing 18 and sprockets 90a and 90bconnected to the upper housing 20, the lengths of legs 62f and 62g ofchain 62 will be inversely proportional, so as to maintain the overalllength of chain 62. A tension pulley 92 is adjustably mounted in a slot94 to provide a biasing force against leg 62d of chain 62, to maintaintension throughout the chain loop 62. As shown in FIG. 1, a drive motor96 is connected to sprocket 90a in order to drive the chains 62 aboutthe system.

Referring now to FIGS. 8-11, a specimen carrier 16 is shown in moredetail. Specimen carrier 16 is preferably formed of a solid block ofplastic material, with forward and rearward faces 16a and 16b, right andleft ends 16c and 16d, and top and bottom surfaces 16e and 16f. A cavity98 is provided for retaining a specimen tube 100 in a generally uprightorientation, and a generally rectangular slot 102 is provided forretaining a specimen slide in specimen carrier 16. A pair of wings 104and 106 project outwardly in opposite directions from the forward andrearward faces 16a and 16b respectively, and are located adjacent thetop surface 16e of specimen carrier 16. Wings 104 and 106 are identical,and therefore only wing 104 will be described in detail herein.

Referring now to FIG. 10, wing 104 includes an upper surface 104a, and alower surface 104b, each projecting outwardly from forward face 16a ofcarrier 16. A generally semicylindrical notch 108 is formed in lowersurface 104b and extends orthogonally from forward face 16a of carrier16, to receive lift pins 60 therein. Preferably, lower surface 104bslopes upwardly towards carrier top surface 16d from diametric sides ofnotch 108, to form a generally inverted triangular shape, as shown inFIG. 10. As shown in FIG. 9, wings 104 and 106 project outwardly fromforward and rearward faces 16a and 16b, and are centered between ends16c and 16d. Preferably, wings 104 and 106 have a length less than thefull length of forward and rearward faces 16a and 16b. A correspondingnotch 108' is formed in wing 106, as shown in FIG. 9.

Whereas the invention has been shown and described in connection withthe preferred embodiment thereof, many modifications, substitutions andadditions may be made which are within the intended broad scope of theappended claims.

I claim:
 1. An elevator for moving a specimen carrier between verticallyspaced apart conveyor tracks, comprising:an elevator having an upperhousing removably connected to an upstream end of an upper conveyortrack and having a lower housing removably connected to a downstream endof a lower conveyor track; each said conveyor track having a movingsupport surface for transporting a specimen carrier downstream, and apair of arms projecting upwardly on opposing sides of the supportsurface for guiding a specimen carrier; said elevator including meansfor lifting a specimen carrier vertically upwardly off of the downstreamend of the lower track and placing a lifted specimen carrier verticallydownwardly on to the upstream end of the upper track; said means forlifting and placing a specimen carrier including a pair of opposing,spaced apart, elongated lift members having coaxial longitudinal axesoperably mounted to move in a continuous, closed loop between the lowertrack downstream end and upper track upstream end; and each specimencarrier including opposingly disposed wings cooperable with the liftmembers to selectively receive opposing free ends of the lift members.2. The elevator of claim 1, wherein said upper and lower housings areselectively and adjustably connected together, to permit selectiveadjustment of an overall height of the elevator.
 3. The elevator ofclaim 2, wherein said upper housing is generally L-shaped, with ahorizontal leg portion and a vertical back portion;wherein said lowerhousing is generally L-shaped, with a horizontal leg portion and avertical back portion; said upper and lower housing back portions beingselectively, slidably connected in vertical alignment to permitadjustment of a distance between the upper and lower housing legs. 4.The elevator of claim 3:wherein said upper housing includes forward andrearward spaced apart and parallel plates, said upper track upstream endconnected to said elevator within the upper housing leg between saidplates; and wherein said lower housing includes forward and rearwardspaced apart and parallel plates, said lower track downstream endconnected to said elevator within the lower housing leg, between saidplates.
 5. The elevator of claim 1:wherein said upper housing isgenerally L-shaped, with a horizontal leg portion and a depending backportion; wherein said lower housing is generally L-shaped, with ahorizontal leg portion and an upwardly projecting back portion; saidupper and lower housing back portions being connected in verticalalignment, with the corresponding leg portions projecting in opposingdirections.
 6. The elevator of claim 5, wherein said elevator housingsare enclosed, and further comprising:an opening in the lower housing legfor receiving a specimen carrier transported on the lower track withinthe lower housing; an opening in the upper housing leg for permittingdeparture of a specimen carrier transported on the upper track fromwithin the upper housing; said means for lifting and placing a specimencarrier being positioned to transport a specimen carrier from the lowertrack to the upper track entirely within said upper and lower housings.7. The elevator of claim 1, wherein said means for lifting and placing aspecimen carrier further includes:a pair of continuous loop chainsengaged around a plurality of pairs of spaced apart coaxial sprockets; adrive motor operably connected to a pair of drive sprockets engaged withsaid pair of chains to selectively drive the same; said pair of liftmembers including one lift member attached to one of said pair ofchains, and the opposing lift member attached to the second of said pairof chains.
 8. The elevator of claim 7, further comprising a plurality ofpairs of lift members attached along said pair of chains and spaceduniformly apart therealong.
 9. The elevator of claim 7, wherein saidmeans for lifting and placing a specimen carrier further includes:afirst sprocket pair rotatably mounted in the lower housing on opposingsides of the lower conveyor track; said pair of chains forming a chainloop with a first leg extending between the first sprocket pair and asecond sprocket pair; a stop plate mounted over the support surface ofthe lower conveyor track and located to stop a specimen carrier on thelower track transport surface with the specimen carrier's wings alignedvertically with the first leg of the chain loop to receive the liftmembers; a second sprocket pair rotatably mounted in the upper housingdirectly above the first sprocket pair, such that the first leg of thechain loop is generally vertical.